Method of forming connector with flange and shaft

ABSTRACT

The method includes first defining a longitudinal channel in a major body, the major body including a first portion, a second portion and a flange, the flange being located between the first portion and the second portion, the longitudinal channel traversing through a longitudinal length of the major body from the first portion through the second portion, the first portion including a shaft, and second defining a first side end of the flange, the first side end at least partially defining a first segment of at least one first airflow inlet, the first segment being in communication with the longitudinal channel.

PRIORITY CLAIM

This application is a Divisional of U.S. application Ser. No. 17/947,477, filed Sep. 19, 2022, which is a Divisional of U.S. application Ser. No. 17/066,664, filed Oct. 9, 2020, which is a Divisional of U.S. application Ser. No. 15/980,329, filed May 15, 2018, which is a Divisional of U.S. application Ser. No. 15/492,290, filed Apr. 20, 2017, which is a Continuation of U.S. application Ser. No. 14/051,029, filed Oct. 10, 2013, which claims priority as a Continuation to PCT Application No. PCT/US2012/033329, filed on Apr. 12, 2012, which claims priority to U.S. Provisional Patent Application No. 61/474,569, filed on Apr. 12, 2011, the disclosures of each of which are incorporated by reference in their entirety.

BACKGROUND Field

This invention relates generally to electronic cigarettes and more specifically to a battery connector for an electronic cigarette having a side air intake for improved air in-flow and out-flow through the electronic cigarette.

Related Art

Electronic cigarettes are becoming a popular alternative to tobacco smoking because of the many advantages that they offer. One of the main reasons that they are popular is due to their similarities to tobacco smoking. In fact, the closer that they are in providing the experience of a traditional cigarette, the more likely they are to be accepted in the market place.

An electronic cigarette typically comprises a battery, an atomizer, a container of smoke juice, a heating element and a power control circuit. The battery is used to power the circuit and the atomizer, where the atomizer heats the smoke juice to create smoke or vapor, which is inhaled by a user.

One example of an electronic cigarette (hereinafter an “Electronic Cigarette” or “E-cigarette”) is a “two-piece” device having a first battery section and a second atomizer section, wherein the atomizer section is detachable from the battery section.

An example of one such Electronic Cigarette is shown in FIGS. 1 and 2 . In some embodiments, the battery section B contains a power cell, an airflow sensor, and a chipset (hereinafter referred to as, the Battery). In some embodiments, the atomizer section A contains a heating element and a container of “smoke juice” which comprises flavorings and a vaporizing base, such as glycol (hereinafter referred to as a “Cartomizer”). Typically, the Battery and Cartomizer are physically and electrically connected by a threaded engagement. In some embodiments, the Battery has the “male” threaded portion and the Cartomizer has the “female” threaded portion, as shown in FIG. 2 .

In the beginning stages of development of the Electronic Cigarette, it was natural to copy the air flow and to mimic its path similar to the way it behaves in a traditional cigarette. In a tobacco cigarette, air enters the tip, which collects the smoke and enters the smoker's mouth through the “filter.” Likewise, early E-cigarettes had one or more notches at the tip of the Battery to allow air intake. Air would enter from the tip, pass through the entire Battery, and continue through the Cartomizer, the vapor-producing portion of the E-cigarette, and enter the smoker's mouth via the distal end of the Cartomizer, which functions as a mouth piece.

A cross-section of an example of this arrangement can be seen in FIG. 3 . As shown in FIG. 3 , when air 104 is inhaled through the mouthpiece 100, air enters the tip of the cigarette, travels past an air flow sensor 102 through the spaces provided around the sensor 102, and continues past the battery B (in this case a lithium cell.) It then goes through the opening in the axis of a post engaged with the Battery's male connector 106, and straight into a post 108 engaged to the female connector of the Cartomizer. The air is then inundated with atomized particles of liquid vapor and exits through the mouthpiece of the Cartomizer into the smoker's mouth.

Heretofore, there has often been a specific problem with tip-intake Electronic Cigarettes that the present invention aims to eliminate. When the smoker exhales into a tip-intake battery Electronic Cigarette (as smokers often do), the vapors 104A from the mouth follow the reverse of the path described above—they flow inside the Battery towards the sensor and often condense causing the sensor to become clogged and fail. The exhalation likewise causes excess liquid in the Cartomizer to follow the same path into the Battery part towards the sensor, clogging it further and also causing it to fail. This also causes major difficulties in mass-production in terms of maintaining consistent air flow and consistent sensitivity of the sensor from one Electronic Cigarette to the next.

Therefore it is desirable to avoid bringing the intake air through the entire length of the Battery through its rear tip (hereinafter “Tip-Intake”), and instead to bring it in through its front side (hereinafter “Side-Intake”), at the point where the Battery and Cartomizer sections meet.

However, it was always perceived as a necessity for the female threaded portion of the Cartomizer to have air slits at its edges when used in conjunction with a Side Intake Battery, because it was otherwise difficult to mass-produce machined male threads that allow air intake at its base. As a result, if it was desirable to change the design of the E-cigarette from the Tip-Intake type to the Side-Intake type, one would necessarily need to modify the female portion of the E-cigarette, i.e. the Cartomizer. Therefore, if it was desirable to make slits on the Battery section of the E-cigarette, one would need to redesign the entire E-cigarette so that the Battery section would be the female threaded portion and the Cartomizer section would be the male threaded portion. Additionally, one could never offer an option of interchanging the male Battery section between the Tip-Intake type with the Side-Intake type, while maintaining compatibility with the same female portion, since in the latter, the female Cartomizer would require slits at the engagement point, whereas in the former, the female Cartomizer could not have slits, otherwise the resulting airflow through the E-cigarette would be too great.

Accordingly, implementation of a Side-Intake Electronic Cigarette has, until the present invention, been considered an expensive and complicated proposition which would, by necessity, require redesign of all parts of the device and eliminate the possibility of backwards-compatibility of the majority of internal parts of the device.

SUMMARY

The present invention resolves the above problems and provide an air intake path from the side of the E-cigarette via modification to the male Battery connector, without modifying the female Cartomizer connector, while maintaining ease of manufacture—especially ease of machining the male Battery connector during mass production, and backwards compatibility whereas the same un-slited female Cartomizer could be used together with the male Battery connector for both the Tip-Intake and Side-Intake types of E-cigarettes.

The present invention also provides the possibility to create an air path that will allow a silent air intake, unlike other Side-Intake solutions that generate substantial hissing noise as the air enters from the side.

A cross-section of an Electronic Cigarette utilizing the Battery connector of the present invention is shown in FIG. 4 . As can be seen there, the spaces 110 around the sensor are blocked so no air flow takes place through the cavity of the battery part. During inhalation, air 104 enters from the side 112 of the Battery and enters the post 108 of the Battery B via a groove in the battery post. It then enters into the Cartomizer A through the axial opening in the Cartomizer post and exits the Cartomizer into the smoker's mouth. Although there is also provided an opening 114 into the Battery through the battery post, there is minimal air or vapor flow through said opening 114 (hereinafter “pressure differential channel” 114) because the spaces 110 around the sensor are blocked. As a result, during inhalation, the sensor 102 can detect a pressure differential via said pressure differential channel 114.

During exhalation, the vapors do not enter into the battery part towards the sensor; they travel out through the side vents, opposite to the direction that air entered upon inhalation. Such a construction greatly extends the life of the product.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an assembled view of a typical two-piece electronic cigarette.

FIG. 2 is a disassembled view of a typical two-piece electronic cigarette.

FIG. 3 is a cross-sectional view of an electronic cigarette in the prior art showing inhaled and exhaled air paths.

FIG. 4 is a cross-sectional view of an electronic cigarette using the novel connector herein described showing inhaled and exhaled air paths.

FIGS. 5-13 are alternative embodiments of the connector of the present invention showing various arrangements of side vent apertures.

FIGS. 14-15 illustrate an alternative embodiment of a connector of the present invention with a battery post of the present invention.

FIG. 16 is a cross-sectional view of an electronic cigarette using the connector and battery post shown in FIGS. 13-15 .

FIG. 17 illustrates an alternative embodiment of a battery post of the present invention.

FIG. 18 is a cross-sectional view of an electronic cigarette using the connector of FIG. 13 and the battery post of FIG. 17 .

DETAILED DESCRIPTION

The present invention concerns various embodiments of a Battery-Cartomizer connector for an Electronic Cigarette that creates an air-intake path that enters through the male connector (i.e. the Battery section), without the need to modify the female connector (i.e. the Cartomizer section) thereof. Accordingly, the present invention permits flexibility of design and product diversification for the E-cigarette manufacturer, maintains ease of manufacture and mass-production, and creates additional advantages such as reducing noise and hissing during air-intake (i.e. a “puff or “drag”).

FIGS. 5-13 depict various embodiments of the connector of the present invention. It is understood that these figures depict a sectional view of an E-cigarette connector 1, which joins the Battery section to the Cartomizer section by a threaded engagement. As shown in FIGS. 5-13 , it is intended that the male Battery connector M at the proximal end 3 of the connector mates to a female portion of a Cartomizer, and the distal end 5 of the connector is attached, through a pressure or friction fit, or through other suitable means, to the Battery portion B (not shown) and functions as a “cap” thereof.

In some embodiments of the present invention, an air intake path starts at the outer circumference of the connector 1 between the Battery and the Cartomizer of the E-cigarette, running inside notch 9 on connector 1. The air is thus brought into the Battery through grooves 10 formed on the attachment (i.e., non-threaded) distal end 5 of the connector. Once inside the battery, the air path loops around and exits the Battery housing towards the Cartomizer, via a hole along the central axis of connector 1. In accordance with the desired air-intake path, notch 9 is cut out on the side of connector 1 at strategic location and with strategic geometry.

In most E-cigarettes, connector 1 has a flange 7 that appears from the outside as a metallic ring when the separate parts of the E-cigarette are screwed together, like that shown in FIG. 1 . The resulting ring is usually very thin, and has little purpose other than cosmetic—to create a decorative divider between the two major parts of the E-cigarette (i.e. the Battery section and the Cartomizer section) and to cover the inside edge of the Battery housing. Cutting into this ring or removing a portion of it to create the desired air-intake characteristics of the present invention would expose the dull edge of the Battery housing and detracts from the esthetics of the product. However, in some embodiments of the present invention, the thickness of the flange is increased so that a portion of it can be cut or milled away, resulting in notch 9, while the remaining portion of the flange thickness will still retain the aesthetic design and still cover the internal edge of the housing.

Accordingly, as shown in FIG. 5 , in some embodiments of connector 1, notch 9 begins at the outer perimeter of the flange 7, toward distal end 5 and travels toward the center axis of flange 7, resulting in a rectangular shape.

In some embodiments, such as in FIG. 6 , aperture 11 is bored through the wall of the distal end 5 of connector 1 at substantially the same radial location as notch 9. This configuration increases the air-intake volume, permitting less-constricted air flow through the connector 1 and the Battery section.

In some embodiments, such as in FIG. 7 , slot 13 is milled along the curved wall of the distal end 5 of connector 1, with notch 9 located substantially across from the center of slot 13, radially. As shown, slot 13 is oriented perpendicular to the longitudinal axis of connector 1.

In some embodiments, such as in FIG. 8 , channel 15 is milled across the outer surface of the distal end 5 of connector 1, beginning at notch 9 and terminating at the end of distal end 5. In this configuration, notch 9 has a substantially curved profile that transitions uniformly into channel 15. In this configuration, channel 15 is milled substantially parallel to the longitudinal axis of connector 1.

In some embodiments, such as in FIG. 9 , fanned channel 17 is milled across the outer surface of the distal end 5 of connector 1, beginning at notch 9 and terminating at the end of distal end 5. Notch 9 has a substantially curved profile that transitions into fanned channel 17. Fanned channel 17 is milled substantially parallel to the longitudinal axis of connector 1.

In some embodiments, such as in FIG. 10 , channel 19 is milled away all around the outer circumference of flange 7, along its distal edge. The purpose of channel 19 is to allow for air intake even when a user happens to hold his finger over notch 9 during smoking. When that happens, air enters channel 19 and runs along the channel until it reaches and enters notch 9.

In some embodiments, such as in FIG. 11 , channel 21 is milled away all around the outer circumference of flange 7, substantially in the middle of the flange. Several apertures 23 are bored through the wall of the flange. The purpose of channel 21 is to allow for air intake even when a user holds his finger over an aperture 23 during smoking. When that happens, air enters channel 21 and runs along the channel until it reaches and enters an aperture 23.

In some embodiments, such as in FIG. 12 , notch 25 is cut out through the wall of flange 7 on the side of connector 1 at strategic location and with strategic geometry. Slot 27 is cut out of the distal end 5 of connector 1, beginning at notch 25 and terminating at the end of distal end 5. In this configuration, notch 25 has a rectangular profile that transitions uniformly into slot 27.

Another embodiment of the connector of the present invention is shown in FIGS. 13-15 . FIG. 13 shows the connector without a battery post, FIG. 14 shows the battery post and FIG. 15 shows the battery post and connector assembled. As shown in FIG. 13 , instead of a notch in the outer perimeter of the flange 7, toward distal end 5, perpendicular surface channels 30 are drilled on shelf 31 of flange 7. The channels continue and penetrate through the shaft 32 of connector 1 (in which threads are not shown for purposes of clarity) at orifices 33 and continue through inner shelf 45. The engaging battery post 34, shown in FIG. 14 , includes a longitudinal orifice 35 (beginning on the surface of post head 37 and continuing longitudinally completely through the post) that forms the pressure differential channel, as well as a groove 36 which assists in guiding air inhaled or exhaled through perpendicular surface channel 30 and orifice 33.

It should be noted here that although in FIG. 15 groove 36 is shown aligned with perpendicular surface channel 30 and orifice 33, because the outer diameter of post head 37 is smaller than the inner diameter of shaft 32, such alignment is not necessary to allow for unimpeded air flow through connector 1.

The airflow 104 through the connector and battery post combination shown in FIGS. 13-15 is illustrated in FIG. 16 . As shown in FIG. 16 , one possible draw-back of this arrangement is that upon exhalation, any excess fluid 116 (vapor, saliva, etc.) could be blown through orifice 35, into the pressure differential channel and into the Battery B.

An alternative embodiment for a battery post designed to minimize this problem is shown in FIG. 17 . As shown in this figure, there is no orifice drilled through post head 37. Rather, the air path to the pressure differential channel is created by channel 38 which is drilled beneath groove 36 on the side 39 of post head 37. Channel 38 perpendicularly intersected by the pressure differential channel (not shown) which is drilled longitudinally from battery post end 40.

The airflow through a connector such as that shown in FIG. 13 using the battery post shown in FIG. 17 is illustrated in FIG. 18 . As is shown in this figure, there is no direct path for excess liquid 116 to migrate into the Battery compartment B.

The connector 1 of the present invention has an additional major advantage in that those embodiments shown in FIGS. 5-18 allow for a substantially silent air-intake without the excessive hissing or noise associated with other known E-cigarettes. Another major advantage of the present invention is its application in newly introduced V-Go and E-go (large-capacity electronic cigarettes) E-cigarettes. V-go and E-go E-cigarettes, which almost always have a side-intake, cannot be used with non-vented female Cartomizers. Heretofore manufacturers always had to resort either to vented female Cartomizers or non-vented male Cartomizers. However, with the present invention, it is possible to create V-go and E-go E-cigarettes that will be interchangeable with Tip-Intake E-cigarettes so that they are compatible with the same existing female unvented Cartomizers, without the need to modify the Cartomizers.

It should be appreciated that although the above-described embodiments demonstrate that some embodiments of the present invention are designed such that the Battery comprises the “male” connection and the Cartomizer comprises the “female” connection, the reverse configuration may be equally suitable, depending on design requirements. Accordingly, the Cartomizer may comprise the “male” connection and the Battery may comprise the “female” connection.

It will be understood that the preferred embodiments of the present invention have been disclosed by way of example and that other modifications and alterations may occur to those skilled in the art without departing from the scope of the disclosure herein. 

1. (canceled)
 2. A method of forming a connector, comprising: first defining a longitudinal channel in a major body, the major body including a first portion, a second portion and a flange, the flange being located between the first portion and the second portion, the longitudinal channel traversing through a longitudinal length of the major body from the first portion through the second portion, the first portion including a shaft; and second defining a first side end of the flange, the first side end at least partially defining a first segment of at least one first airflow inlet, the first segment being in communication with the longitudinal channel.
 3. The method of claim 2, wherein the first side end faces the first portion.
 4. The method of claim 3, wherein the second defining defines a step that faces the shaft, a part of the step at least partially defining the first segment.
 5. The method of claim 3, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being in communication with the first segment and the longitudinal channel.
 6. The method of claim 3, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being between the first segment and the longitudinal channel.
 7. The method of claim 5, wherein the third defining defines such that the second segment is an aperture that is at least partially defined within a sidewall of the shaft.
 8. The method of claim 5, wherein the at least one first airflow inlet includes a first airflow inlet and a second airflow inlet, and the second defining defines a step that at least partially defines the first segment for the at least one first airflow inlet and the second airflow inlet.
 9. The method of claim 8, wherein the third defining defines the second segment of the first airflow inlet and the second airflow inlet within the shaft, the second segment of the first airflow inlet and the second airflow inlet being evenly spaced apart along a circumference of the shaft.
 10. The method of claim 2, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft.
 11. The method of claim 10, wherein the third defining defines such that the second segment is an aperture that is at least partially defined within a sidewall of the shaft.
 12. The method of claim 10, wherein the third defining defines the second segment to be in communication with the first segment and the longitudinal channel.
 13. The method of claim 11, wherein the at least one first airflow inlet includes a first airflow inlet and a second airflow inlet, and the second defining defines the first segment of the first airflow inlet and the second airflow inlet with the first side end of the flange, the first airflow inlet and the second airflow inlet being in communication with the longitudinal channel.
 14. The method of claim 13, wherein the third defining defines the second segment of the first airflow inlet and the second airflow inlet within the shaft, the second segment of the first airflow inlet and the second airflow inlet being in communication with the first segment of the first airflow inlet and the second airflow inlet, respectively, the second segment of the first airflow inlet and the second airflow inlet being evenly spaced apart along a circumference of the shaft.
 15. The method of claim 2, wherein a first diameter of the first portion of the major body is smaller than a second diameter of the second portion of the major body, and a third diameter of the flange is larger than the second diameter.
 16. The method of claim 2, further comprising: connecting a first section to a second section with the connector to form an assembled e-vaping device, the first section and the second section being e-vaping elements.
 17. The method of claim 16, wherein the second defining defines a step that faces the shaft, a part of the step defining the first segment, the first side end facing the first portion.
 18. The method of claim 16, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being fluidly connected to the first segment and the longitudinal channel within the assembled e-vaping device.
 19. The method of claim 18, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the first segment and the second segment fluidly connecting the longitudinal channel to ambient air within the assembled e-vaping device.
 20. The method of claim 16, wherein the connecting connects such that a first external surface of the flange forms a portion of an outer surface of the assembled e-vaping device.
 21. The method of claim 20, wherein the connecting connects such that the second portion and the first portion of the major body fits at least partially within a first end of the first section and a second end of the second section, respectively, and a second side edge of the second end of second section further defines the first segment of the at least one first airflow inlet.
 22. The method of claim 21, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being in fluid communication with the first segment and the longitudinal channel once the first section is connected to the second section with the connector. 